Hard-shell thoracolumbar sacral orthoses (TLSOs) are used for treating idiopathic scoliosis, a deformation of the spine with a sideways curvature. The pressure required inside the TLSO for ideal corrective results remains unclear. Retrofitting TLSOs with commercially available pressure measurement systems is expensive and can only be performed in a laboratory. The aim of this study was to develop a cost-effective but accurate pressure sensor system for TLSOs. The sensor was built from a piezoresistive polymer, placed between two closed-cell foam liners, and evaluated with a material testing machine. Because foams are energy absorbers, the pressure-conductance curve was affected by hysteresis. The sensor was calibrated on a force plate with the transitions from loading to unloading used to establish the calibration curve. The root mean square error was 12% on average within the required pressure range of 0.01-0.13 MPa. The sensor reacted to the changing pressure during breathing and different activities when tested underneath a chest belt at different tensions. The peak pressure reached 0.135 MPa. The sensor was further tested inside the scoliosis brace during different activities. The measured pressure was 0.014-0.124 MPa. The results from this study enable cheaper and mobile systems to be used for clinical studies on the comfort and pressure of braces during daily activities.
Keywords: calibration; cost-effective development; foam properties; hysteresis; pressure sensor; scoliosis brace.